Method of welding a laminate and product produced thereby



Jan. 13, 1970 A. R. WILLIAMS 3,4

METHOD OF WELDING A LAMINATE AND PRODUCT PRODUCED THEREBY Filed June 29, 1967 2 Sheets-Sheet 1 TE: 1. 4.0. p y 26 I8 I20 I60 I 12b I60 1 i A e --a 4.0. 26 pp y 2402 2 2 2 2 [2a 2 22a 10 I I I602 18 A -A Y a --a M0 18 a rm. 4- 20a 20b 4 I8 [6'0 0 1 i I '3 Q 18 INVENTOR. 8 ALVIN R. WILLIAMS A f rorney United States Patent 3,489,446 METHOD OF WELDING A LAMINATE AND PRODUCT PRODUCED THEREBY Alvin R. Wiiliams, Northfield, Ohio, assignor to United States Steel Corporation, a corporation of Delaware Filed June 29, 1967, Ser. No. 650,042 Int. Cl. F161) 1/00, 5/00, 7/00 U.S. Cl. 287-189.36 12 Claims ABSTRACT OF THE DISCLOSURE BACKGROUND OF THE INVENTION In the manufacture of drums, vats and the like and, in particular, in the welding of adhesively clad sheets, particularly stainless and carbon steel for such products, it is advantageous to have the stainless steel continuous over the entire inner surface of the product, a feat diflicult to achieve at the seam or joint of the product. The joint or seam is usually spot welded or continuously seam welded. If dissimilar metals are adjacent each other in the weld area of the joint welding, difficulties are encountered because of the different electrical heat conductivity of the dissimilar materials.

Conventional methods of and apparatus for welding similar products are of the type shown in the following patents:

US. Patent Nos. 675,357, Maeconochie, May 28, 1901; 706,635, Booth, Aug. 12, 1902; 1,495,653, Thomas et al., May 27, 1924; 1,161,164, Sexton, Nov. 23, 1915; 2,050,- 326, Hopkins, Sept. 11., 1936; 2,120,461, Capeman, June 14, 1938; 2,181,319, Flugge, Nov. 28, 1939; 2,187,740, Hothersall, Jan. 23, 1940; 2,198,630, McManus, Apr. 30, 1940; 2,214,422, Kronquest, Sept. 10, 1940; 2,231,407, Castor et al., Feb. 11, 1941; 2,250,617, Argentin, July 29, 1941; 2,326,815, Wobbe, Aug. 17, 1943; 2,343,255, Pray et al., Feb. 29, 1944; 2,354,855, Emanuel, Aug. 1, 1944; 2,359,775, McManus et al., Oct. 10, 1944; 2,426,820, Evans, Sept. 2, 1947; 2,641,674, Orr et al., June 9, 1953; 2,797,843, Orlins, July 2, 1957; and 3,019,- 753, Orlins, Feb. 6, 1962.

OBJECTS OF THE INVENTION It is the general object of this invention to avoid and overcome the foregoing and other difficulties of and objections to prior art practices by the provision of an improved method of welding together adhesively bonded laminates to provide a seam where like metals only are in contact with each other and an improved welded joint produced by such method.

BRIEF SUMMARY OF THE INVENTION The aforesaid objects of this invention, and other objects which will become apparent as the description proceeds, are achieved by providing a welded product or joint and a method of welding together adhesively bonded laminates to provide a seam or joint where like metals only are in contact. The welded joint between a first portion and a second portion of an adhesively bonded laminate is adapted to provide a noble metal protective surface on a predetermined side of the laminate. The first portion and the second portion have a noble metal member, a base metal member, and a substantially eelctrically insulating adhesive between the noble metal member and the base metal member. The welded joint has the first portion provided with an adhesive free first marginal portion. One of the noble metal member and the base metal member in the first marginal portion is formed to provide a first cavity between the one and the other of the noble metal member and the base metal member in the first marginal portion. The second portion is disposed in the first cavity so that the noble metal member of the first portion is adjacent the noble metal member of the second portion and the first portion is welded to the second portion adjacent the first marginal portion.

The method of forming a welded joint between a first portion and a second portion of an adhesively bonded laminate is adapted to provide a noble metal protective surface on a predetermined side of the laminate. The first portion and the second portion have a noble metal member, a base metal member and an electrically insulating adhesive between the noble metal member and the base metal member. The method includes the steps of providing the first portion with an adhesive free first marginal portion, forming one of the noble metal member and base metal member in the first marginal portion to provide a first cavity between the one and the other of the noble member and the base metal member in the first marginal portion, disposing the second portion in the first cavity so that the noble metal member of the first portion is adjacent the noble metal member of the second portion, and welding the first portion to the second portion adjacent the first marginal portion.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS For a better understanding of this invention, reference should be had to the accompanying drawings, wherein like numerals of reference indicate similar parts throughout the several views and wherein:

FIGURE 1 is a diagrammatic side elevational view of the joint of the invention for a drum, vat or the like prior to welding and showing the first portion of the laminate having an adhesive free marginal portion, the noble metal members of both portions of the laminate on the inner surface, the noble metal member of the first portion formed to provide a cavity, the second portion of the laminate disposed in the cavity, and a pair of lap welding electrodes;

FIGURE 2 is a view similar to FIGURE 1 showing the noble metal members of both portions of the laminate on the inner surface, the base metal member of the first portion of the laminate, the second portion of the lamiate disposed in the cavity formed to provide a cavity, and movable welding electrodes for a continuous seam weld;

FIGURE 3 is a view similar to FIGURES 1, 2 with the electrodes removed for clarity and showing the second portion of the laminate also having an adhesive free marginal portion, the noble metal members of both portions of the laminate on the inner surface, the noble metal member of the first portion of the laminate and the second portion of the laminate formed to provide a cavity disposed in the cavity and welded to the first portion;

FIGURE 4 is a view similar to FIGURE 3 showing the noble metal members of both portions of the laminate on the inner surface, the base metal member of the first portion of the laminate formed to provide the cavity, adhesive free marginal portions on the first portion and the second portion of the laminate and the second portion of the laminate disposed in the cavity and welded to the first portion;

FIGURE 5 is a view similar to FIGURES 3, 4 showing the noble metal members of both portions of the laminate on the inner surface, both portions of the laminate provided with an adhesive free marginal portion, the noble metal member of the first portion of the laminate formed to provide a cavity and the base metal member of the second portion cut away to permit butt welding of the adjacent base metal members;

FIGURE 6 is a view similar to FIGURES 3-5 showing both portions of the laminate provided with adhesive free marginal portions, the base metal member of the first portion of the laminate formed to provide cavity, the noble metal member of the second portion cut away and the adjacent noble metal members butt welded together on the inner surface;

FIGURE 7 is a view similar to FIGURES 3-6 showing the noble metal members of both portions of the laminate on the inner surface, both portions of the laminate having an adhesive free marginal portion, a noble metal member and a base metal member of the first portion of the laminate formed to provide a cavity and the second portion of the laminate disposed in the cavity and welded to the first portion;

FIGURE 8 is a view similar to FIGURES 3-7 showing the noble metal members of both portions of the laminate on the inner surface, the base metal member of the first portion of the laminate formed to provide a first cavity, a noble metal member of the second portion of the laminate formed to provide a second cavity and the two portions of the laminate welded in an interlocking arrangement; and

FIGURE 9 is a view similar to FIGURES 1-8 showing two laminates positioned for a seam weld.

Although the principles of this invention are broadly applicable to welding, this invention is particularly adapted for use in conjunction with a welded joint or seam for a drum, vat or the like between two portions of an adhesively bonded laminate or between two bonded laminates and hence it has been so illustrated and will be so described.

DETAILED DESCRIPTION With specific reference to the form of this invention illustrated in the drawings, and referring particularly to FIGURE 1, a joint to be welded for a drum, vat or the like is indicated generally by the reference numeral 10.

This joint 10 is between a first portion 12a and a second portion 12b of an adhesively bonded laminate and such joint 10 is adapted to provide a noble metal protective surface on a predetermined side of the laminate, in this case, as viewed in FIGURE 1, the inner or bottom side of such drumb, vat or the like. This first portion 12a and second portion 12b have noble metal members 14a, 1417 respectively (suitably stainless steel or the like), base metal members 16a, 16b (suitably carbon steel or the like) and a substantailly electrically insulating adhesive 18 disposed between the noble metal members 14a, 14b and the base metal members 16a, 16b. A suitable adhesive 18 is Cybond 4000 adhesive, the trade name of American Cyanamid Laboratories for a polyurethane adhesive.

It will be understood that any other laminate, such as stainless steel on galvanized steel, aluminum on steel, copper on aluminum, bronze on galvanized steel, stainless steel on lead or the like may be employed. Further, other adhesives, such as the following, may be employed:

Trademark or trade name: Manufacturer Surlyn A ionomer resin E. I. du Pont de Nemours & Co. Bakelite phenoxy resins PKHH and PA] H Union Carbide Corporation. Scotch-Weld brand structural adhesives 3M Company. A-1103-B adhesive B. F. Goodrich Industrial Products Company. USS Nexus PQE-l polymeric material United States Steel Corporation.

The first portion 12a is provided with an adhesive free first marginal portion 20a. One of the noble metal member 14:: and the base metal member 16a in the first marginal portion 20a (in this case the stainless steel 14a) is formed or bent outwardly from the longitudinal axis A-A of the first portion 12a to provide a first cavity 22a between the stainless steel 14a and other of the stainless steel 14a and the carbon steel 16a (in this case the carbon steel 16a). The left-hand end of the second portion 12b, as viewed in FIGURE 1, is disposed in the first cavity 22a so that the stainless steel 16b of the second portion 12b is adjacent the stainless steel 16a of the first portion 12a and with the longitudinal axis B-B of the second portion 12b disposed a distance D from the longitudinal axis A-A of the first portion 12a.

The first portion 12a is welded to the second portion 12b adjacent the first marginal portion 20a by lap welding type electrodes 24a, 24b connected through a switch 26 to a suitable supply indicated by the legend AC Supply. The welding current flows from electrode 24a to electrode 24b until the adhesive 18 in the left-hand end of the second portion 12b (FIGURE 1) reaches its softening temperature, whereupon the electrodes 24a, 24b compress the carbon steel 16b against the stainless steel 14b and welding current rapidly flows across the second portion 12b to weld the first portion 12a to the second portion 12b.

ALTERNATIVE EMBODIMENTS It will be understood by those skilled in the art that alternatively, as shown in FIGURE 2, the joint 10 to be welded may be a continuous seam, the base metal member 16a. of the first portion 1261 is formed to provide the first cavity 22a and the wheel type electrodes 24:1 24b are employed.

In the welded joint 10 of FIGURE 3 the second portion 12b is provided with an adhesive free second marginal portion 20b to increase welding speed and, as in FIGURE 1, the stainless steel 14a of the first portion 12a is formed to provide the first cavity 22:1

Referring to the welded joint 10 of FIGURE 4, the first marginal portion 20a. and the second marginal portion 20b are used. The carbon steel 16a of the first portion is formed to provide the first cavity 22a In order to provide substantially coinciding longitudinal axes for the welded portions of the first portion 12a and the second portion 12b in the welded joint 10 of FIGURE 5, one of the stainless steel 1412 and the carbon steel 16b of the second portion 12b (in this case the carbon steel MM) is cut away at 28 so that it can be butt welded to the carbon steel 16a of the first portion 12:1

In FIGURE 6 the stainless steel 14b of the second portion 12b is cut away at 28 so that it can be butt welded to the stainless steel 14a of the first portion 12:1 It will be understood that the cut away member may be in either the first portion 12a-. 12a or in the second portion 12b 12b As shown in FIGURE 7 both the carbon steel 16a" and stainless steel 14a of the first portion 12a are formed or bent symmetrically to define the first cavity 22a.

Referring now to the interlocking welded joint 10 shown in FIGURE 8, the carbon steel 16a. of the first portion 12a is formed to provide the first cavity 22a and the stainless steel 14b of the second portion 12b is bent to define the second cavity 221?.

In FIGURE 9, both the first portion 12a and the second portion 12b in the joint 10 to be welded have adhesive free marginal portions 20a", 20b respectively and are arranged for a seam weld with the stainless steel members 14a, 14b on the inside surface.

METHOD It will be understood from the above description that a method is provided for forming a weld joint 10, 10 etc. between a first portion 12a, 12a etc. and second portion 12b, 12b etc. of an adhesively bonded laminate adapted to provide a noble metal protective surface on a predetermined side (i.e. the inner side) of the laminate. This method includes the steps of:

(a) providing the first portion 12a, 12a etc. (FIG- UR-ES 1-9) with an adhesive free first marginal portion 20a, 20a

(b) forming one of the noble metal members 14a, 14a etc. (FIGURES 1-9) and the base metal member 16a, 16a etc. in the first marginal portion 20a, 2011 etc. to provide a first cavity 22a, 2211 etc. between the one and the other of the noble member 14a, 14a etc. and the base metal member 16a, 16a. etc., in the first marginal portion 20a, 20a etc.;

disposing the second portion 12b, 121; etc. (FIG- URES 1-4, 7) in the first cavity 22a, 22a etc. so that the noble metal member 14a, 1411. etc. of the first portion 12a, 12a etc. is adjacent the noble metal member 14a, 14a? etc. of the second portion 12b, 1211 and (d) welding the first portion 12a, 12a etc. (FIGURES 1-9) to the second portion 12b, 12b etc. adjacent the first marginal portion 20a, 20a etc.

Included also are the steps of:

(a) providing the second portion 1212 1211 etc. (FIG- URES 3-9) with an adhesive free second marginal portion 20b 2011 etc.;

(b) oifsetting the first cavity 20a, 20a etc. (FIGURES 14) from the longitudinal axis of the one of the noble metal member 14a, 1441 etc. and the base metal member 16a, 1612 etc. in the first marginal portion 20a, 20a so that the longitudinal axis A-A of the first-portion 12a, 12a etc. is ofiset from the longitudinal axis BB of the second portion 12b, 12b

(c) cutting away one of the noble metal member 14a 14a (FIGURES 5, 6) and the base metal member 16a 16a in the first marginal portion 20a 20a or the second marginal portions so that it can be butt welded to its corresponding metal member of the other portion (i.e. in this case the second portion 12b 12b) and the longitudinal axis A-A of the first portion 12:1 12a substantially coincides with the longitudinal axis BB of the second portion 12b 12b (d) forming the noble metal member 14a (FIGURE 7) and the base metal member 16a in the first marginal portion 20a. to provide the first cavity 20a so that the longitudinal axis A-A of the first portion 12a substantially coincides with the longitudinal axis BB of the second portion 121);

(e) forming one of the noble metal member 14a (FIG- URE 8) and the base metal member 16a in the second marginal portion 20b to provide a second cavity 2211 (f) disposing the first cavity 20a (FIGURE 8) and the second cavity 22a adjacent each other so that the noble metal member 16a of the first portion 12a is adjacent the noble metal member 16a. of the second portion 12b; and

(g) forming a seam weld between the first portion 12a and the second portion 1212 6 SUMMARY OF THE ACHIEVEMENT OF THE OBJECTS OF THE INVENTION It will be recognized by those skilled in the art that the objects of this invention have been achieved by providing an improved method of welding together adhesively bonded laminates to provide a seam where like metals only are in contact with each other and an improved welded joint produced by such method.

While in accordance with the patent statutes preferred and alternative embodiments of this invention have been illustrated and described in detail, it is to be particularly understood that the invention is not limited thereto or thereby.

I claim:

1. A welded joint between a first portion and a second portion of an adhesively bonded laminate adapted to provide a noble metal protective surface on a predetermined side of said laminate, said first portion and said second portion having a noble metal member, a base metal member, and substantially electrically insulating adhesive between said noble metal member and said base metal member, said welded joint having:

(a) said first portion being provided with an adhesive free first marginal portion;

(1) one of said noble metal member and said base metal member in said first marginal portion being formed to provide a first cavity between said one and the other of said noble metal member and said base metal member in said first marginal portion,

(b) said second portion disposed in said first cavity so that said noble metal member of said first portion is adjacent said noble metal member of said second portion, and

(c) said first portion being welded to said second portion adjacent said first marginal portion.

2. The welded joint recited in claim 1 wherein said one of said noble metal member and said base metal member in said first marginal portion being formed is said noble metal member.

3. The welded joint recited in claim 1 wherein said one of said noble metal member and said base metal member in said first marginal portion being formed is said base metal member.

4. The welded joint recited in claim 1 wherein said second portion is provided with an adhesive free second marginal portion.

5. The welded joint recited in claim 1 wherein said first cavity is offset from the longitudinal axis of said one of said noble metal member and said base metal member in said first marginal portion so that the longitudinal axis of said first portion is offset from the longitudinal axis of said second portion.

6. The welded joint recited in claim 4 wherein one of said noble metal member and said base metal member in said first marginal portion of said first portion is cut away so that it can be butt welded to its corresponding metal member of said second portion and the longitudinal axis of said first portion substantially coincides with the longitudinal axis of said second portion.

7. The welded joint recited in claim 6 wherein said one of said noble metal member and said base member in said second marginal portion is the noble metal member.

8. The welded point recited in claim 6 wherein said one of said noble metal member and said base member in said second marginal portion is the base metal member.

9. The welded joint recited in claim 1 wherein said noble metal member and said base metal member in said first marginal portion are formed to provide said first cavity and the longitudinal axis of said first portion substantially coincides with the longitudinal axis of said second portion.

10. The welded joint in claim 4 wherein said noble metal member and said base metal member in said first marginal portion are formed to provide said first cavity and the longitudinal axis of said first portion substantially coincides With the longitudinal axis of said second portion.

11. The welded joint recited in claim 4 wherein one of the noble metal member and said base metal member in said second marginal portion is formed to provide a second cavity, said first cavity and said second cavity being disposed adjacent each other so that said noble metal member of said first portion is adjacent said noble metal member of said second portion. I

12. The Welded joint recited in claim 4 wherein said first portion and said second portion are seam welded.

References Cited UNITED STATES PATENTS 1,162,917 12/1915 Haskin 21991 X 8 Hake 21967 X Field 287189.36'5 X ONeil 21991 X Wolcott 2l967 Watter 219-91 X Williams et al. 21991 X Auld et a1. 285-286 X Ruehlemann 21991 X 10 DAVID J. WILLIAMOWSKY, Primary Examiner WAYNE L. SHEDD, Assistant Examiner US. Cl. X.R.

UNITED STATES PATENT OFFICE CERTIFICATE OF CORRECTION Patent No 3,489 ,446 January 13, 1970 Alvin R. Williams It is certified that error appears in the above identified patent and that said Letters Patent are hereby corrected as shown below:

Column 1, line 34, after "electrical" insert and Column 2, line 9, "eelctrically" should read electrically Column 3, line 64 "drumb" should read drum Column .6 line 65, "point should read joint Signed and sealed this 17th day of November 1970.

(SEAL) Attest:

Edward M. Fletcher, Jr.

Attesting Officer Commissioner of Patents WILLIAM E. SCHUYLER, JR. 

